Kit for a hopper bottom of a particulate material storage container and related method

ABSTRACT

A kit for forming a hopper bottom of a particulate material storage container comprises a generally conical lower section having a tapering diameter from a first end to the second end such that the second end is sized diametrically smaller, and a plurality of arcuate cone segments each defining an inclined concavely curved wall following a generally circular curvature, all of which can collectively form a hopper cone. The arcuate cone segments are connected in an annulus in which the walls of the arcuate cone segments collectively form a generally conical second cone section having a tapering diameter from one end to an opposite end which has a diameter substantially equal to that of the second end of the first cone section. Afterwards, the opposite end of the formed second cone section is connected to the first end of the first cone section so as to form the hopper cone.

FIELD OF THE INVENTION

The present invention relates generally to a kit for a hopper bottom of a particulate material storage container, and more particularly to such a kit which is suitably transportable on a transport truck for later assembly on a site.

BACKGROUND

The largest component of a hopper bottom for a particulate material storage container, such as a grain bin, is its cone, the diameter of which often meets or exceeds the maximum width of a load that is transportable by truck. Thus, restrictions on the size of transportable loads acts to limit the size of such a storage container.

Furthermore, the cost of shipping such a large component can be prohibitive so as to economically constrain or limit the number of units which can be shipped to a common destination and the distance across which such components can be transported.

SUMMARY OF THE INVENTION

According to an aspect of the invention there is provided a kit for forming a hopper bottom of a particulate material storage container, the hopper bottom including a hopper cone, the kit comprising:

a generally conical lower section for forming a first portion of the hopper cone, the lower section encompassing an axis and having a tapering diameter from an upper end defining an opening to a lower end arranged to define a discharge opening of the hopper cone through which particulate material can pass by gravity, the lower section being arranged to receive at its lower end a gate for controlling discharge of the particulate material by gravity out of the hopper cone;

a plurality of arcuate cone segments each having a wall portion defining an upper surface for forming another portion of the hopper cone, the wall portion extending along a circular curvature from a first side to a second side such that the upper surface is concavely curved therebetween and the wall portion being inclined from an arcuate upper end to an arcuate lower end such that the upper surface is inclined therebetween;

the arcuate cone segments being interconnectable to each other in side-by-side relation to form an annulus in which the wall portions form a generally conical upper section having a tapering diameter from an upper end of the upper section which is collectively defined by the arcuate upper ends of the wall portions to a lower end of the upper section collectively defined by the arcuate lower ends of the wall portions, the upper end of the upper section being arranged to receive a cylindrical wall of the storage container and the lower end of the upper section being sized in diameter substantially equal to that of the upper end of the lower section; and the upper section formed by the interconnected arcuate cone segments being connectable at its lower end to the lower section at the upper end thereof so as to collectively form the hopper cone.

This arrangement provides a kit which is transportable on a transport truck for subsequent assembly at a site in which the lower section can be arranged by sizing its upper end in diameter so as to span a width of the transport truck which is measured laterally between opposite sides crosswise to a longitudinal direction of the truck between forward and rear ends which is parallel to a forward transport direction of the transport truck. Thus a relatively large hopper cone can be formed from a limited number of separate components all of which can be readily shipping together on a single transport truck.

Preferably, each arcuate cone segment includes a pair of arcuate load-transfer members each connected to the wall portion and spanning from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the arcuate load-transfer members being spaced from one another in a radial direction of the arcuate cone segment from the arcuate upper end to the arcuate lower end, the arcuate cone segment being interconnectable with another arcuate cone segment in the annulus by lap plates projecting from the arcuate load-transfer members beyond the first side or the second side of the arcuate cone segment for overlapping with the arcuate load-transfer members of said another arcuate cone segment and arranged to receive fasteners passed through the overlapped lap plates and the arcuate load-transfer members.

Preferably, the kit further includes a plurality of legs arranged for connecting to the arcuate cone segments between the arcuate load-transfer members so as to hold the discharge opening of the hopper cone at a spaced height above a support surface on which the hopper bottom is rested.

Preferably, there are provided a plurality of braces to interconnect between the legs and the arcuate cone segments at circumferentially spaced locations from the legs which are arranged to connect between the arcuate load-transfer members.

Preferably, an outer one of the arcuate load-transfer members is disposed at a periphery of the wall portion at the arcuate upper end thereof, and an inner one of the arcuate load-transfer members is disposed at an underside of the wall portion, opposite to the upper surface, intermediate the arcuate upper and lower ends of the wall portion but closer to the arcuate upper end than to the arcuate lower end.

Preferably, each arcuate cone segment includes a connection member connected to the underside of the wall portion adjacent each one of the first and second sides and extending in the radial direction of the arcuate cone segment from the arcuate upper end towards the arcuate lower end, the connection member being arranged for butting engagement with the connection member of another arcuate cone segment in the annulus for forming the upper section and being arranged to receive fasteners through the abutted connection members at radially spaced positions thereon, and each arcuate cone segment further includes an arcuate load-transfer member connected to the wall portion and spanning from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the arcuate cone segment being interconnectable with another arcuate cone segment in the annulus by a lap plate projecting from the arcuate load-transfer member beyond one of the first and second sides for overlapping with the arcuate load-transfer member of said another arcuate cone segment and arranged to receive fasteners passed through the overlapped lap plate and the arcuate load-transfer member. Thus the combination of the abuttable radially extending connection members and at least one arcuate load-transfer member with lap plate provides two types of interconnection of adjacent arcuate cone segments.

Preferably, the lower section includes an annular connection member at the upper end thereof and on an exterior side of the lower section that is arranged to receive fasteners passed therethrough, and each arcuate cone segment includes an arcuate connection member connected to the underside of the wall portion adjacent but recessed from the arcuate lower end and extending in a direction from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the lower end of the upper section formed by the interconnected arcuate cone segments being sized in outer diameter substantially equal to an inner diameter of the upper end of the lower section so that the lower end of the upper section can overlap an interior side of the lower section at its the upper end with the arcuate connection members of the interconnected arcuate cone segments being presented at or adjacent the annular connection member of the lower section for coupling thereto.

The wall portion of each arcuate cone segment may be thickened between the arcuate lower edge and the arcuate connection member so as to strengthen the wall portion for receiving fasteners passed through a thickness thereof when the lower end of the upper section formed by the interconnected arcuate cone segments is overlapped with the interior side at the upper end of the lower section.

The lower section may be thickened between its interior and exterior sides adjacent the annular connection member so as to strengthen the lower section for receiving fasteners passed through a thickness thereof when the upper end of the lower section is overlapped with the lower end of the upper section formed by the interconnected arcuate cone segments.

When the wall portion of each arcuate cone segment is thickened and the lower section is thickened, the fasteners passed through the annular connection member of the lower section and the arcuate connection members of the interconnected arcuate cone segments are offset from the fasteners passed through the thicknesses of the upper and lower sections angularly of the axis of the lower section.

Preferably, each arcuate cone segment including a plurality of stub leg portions connected to the wall portion at spaced locations across the curvature thereof and extending from the underside of the wall portion generally parallel to the axis to lower ends of the stub leg portions which are disposed generally at a common height below the arcuate upper end of the wall portion as the lower end of the wall portion.

Preferably, the kit further includes a plurality of legs distinct from the stub leg portions and sized in height between upper and lower ends of the legs larger than a height of the lower section from the lower end to the upper end thereof, the upper ends of the legs being connectable to the lower ends of the stub leg portions so as to hold the discharge opening at a spaced height above a support surface on which the hopper bottom is rested, the legs being connected to support the hopper cone in fixed relation to the legs including a plurality of braces provided to interconnect between the legs and the arcuate cone segments at circumferentially spaced locations from the stub leg portions.

When the arcuate connection member has a bottom edge disposed below the arcuate lower end, it is preferred that the lower ends of the stub leg portions are disposed at a substantially common height with the bottom edge of the arcuate connection member.

Preferably, the kit further includes a plurality of arcuate footing segments each having a top surface for supporting the lower ends of the legs and a bottom surface arranged for resting on the support surface, the arcuate footing segments each extending along a generally circular curvature from a first end to a second end and being interconnectable to each other in end-to-end relation to form an annulus which is sized to underlie the lower ends of the legs disposed in circumferentially spaced relation about the hopper cone for supporting the hopper bottom on the support surface.

Preferably, each arcuate footing segment comprises at least one linear portion which extends along a substantially linear path from one end to the other and at least one elbow portion which is connected at one of its opposite sides to one of the ends of a respective one of the at least one linear portion, the elbow portion being generally pie-shaped between the opposite sides so as to have a tapering width between the sides from an outer end to an inner end which is arranged to be located radially inwardly of the outer end with respect to the hopper bottom, the elbow portion having a lower surface arranged for resting on the support surface and an upper surface defining a leg-mounting location for receiving the lower end of one of the legs mounted to the elbow portion, the elbow portion defining an internal cavity between the upper and lower surfaces, the opposite sides, and the inner and outer ends, and including a strengthening rib bridging the internal cavity in a direction from the lower surface to the upper surface and disposed beneath the leg-mounting location on the upper surface.

Preferably, the ends of each arcuate footing segment are arranged for butting engagement each with one of the ends of another arcuate footing segment and to receive fasteners passed through the abutted ends of different arcuate footing segments, each arcuate footing segment further including a generally horizontally projecting flange extending beyond one of the ends for resting on top of the adjacent arcuate footing segment when connected in the annulus of the interconnected arcuate footing segments for reducing a shear force exerted on the fasteners passed through the abutted ends.

According to another aspect of the invention there is provided a method for forming a hopper bottom of a particulate material storage container, the hopper bottom including a hopper cone, the method comprising:

providing a kit for forming the hopper cone including:

-   -   a generally conical first cone section having a tapering         diameter from a first end to the second end such that the first         end is sized diametrically larger than the second end;     -   a plurality of arcuate cone segments each defining an inclined         concavely curved wall following a generally circular curvature;

connecting the arcuate cone segments to form an annulus in which the walls of the arcuate cone segments collectively form a generally conical second cone section having a tapering diameter from one end to an opposite end which has a diameter substantially equal to that of the second end of the first cone section;

after the arcuate cone segments are connected in the annulus, connecting the opposite end of the formed second cone section to the first end of the first cone section so as to form the hopper cone.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a hopper bottom according to an arrangement of the present invention;

FIG. 2 is a top plan view of the arrangement of FIG. 1;

FIG. 3 is a side elevational view of the arrangement of FIG. 1;

FIG. 4 is a bottom plan view of the arrangement of FIG. 1;

FIG. 5 is an exploded view of the arrangement of FIG. 1;

FIG. 6 is a bottom plan view of a lower section of the arrangement of FIG. 1;

FIG. 7 is a side elevational view of the lower section of FIG. 6;

FIG. 8 is an elevational view of an arcuate cone segment of the arrangement of FIG. 1;

FIG. 9 is a partial perspective view of a portion of the arcuate cone segment of FIG. 8 with a portion of another arcuate cone segment of the arrangement of FIG. 1;

FIG. 10 is an enlarged elevational view of the area indicated at I in FIG. 8;

FIG. 11 is a bottom plan view of a hopper cone according to a first embodiment of the arrangement of FIG. 1;

FIG. 12 is a partial cross-sectional view along line 12-12 in FIG. 11 of the area indicated at II;

FIG. 13 is an enlarged plan view of the area indicated at III in FIG. 11;

FIG. 14 is a bottom plan view of a hopper cone according to a second embodiment of the arrangement of FIG. 1;

FIG. 15 is a partial cross-sectional view along line 15-15 in FIG. 14 of the area indicated at IV;

FIG. 16 is an enlarged partial view of the area indicated at V in FIG. 14;

FIG. 17 is an enlarged perspective view of the area indicated at VI in FIG. 1;

FIG. 18 is an enlarged perspective view of the area indicated at VII in FIG. 5;

FIG. 19 is an enlarged perspective view of the area indicated at VIII in FIG. 5;

FIG. 20 is a perspective view of an arcuate foot segment of the arrangement of FIG. 1;

FIG. 21 is an enlarged perspective view of the area indicated at IX in FIG. 20;

FIG. 22 is an enlarged perspective view of the area indicated at X in FIG. 5; and

FIG. 23 is an enlarged perspective view of the area indicated at XI in FIG. 1;

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

In the accompanying figures is shown a kit for forming a hopper bottom 1 of a particulate material storage container such as a grain bin. The hopper bottom 1 generally comprises a hopper cone 2, a plurality of legs 3 for supporting the cone with its bottom through which material is discharged at a spaced height above a support surface, and a footing 4 for interconnecting the legs and for resting on the support surface.

Referring to FIGS. 1 and 6-7, the kit comprises a generally conical lower section 11 for forming a first portion of the hopper cone 2. The lower section 11 encompasses an axis A and has a tapering diameter from an upper end 14 defining an opening 15 to a lower end 17 arranged to define a discharge opening 18 of the hopper cone through which particulate material can pass by gravity. That is, the lower end 17 defines an opening 18 which, when the lower section is arranged to form part of the hopper cone, defines the discharge opening. Furthermore, the lower section 11 is in inverted conical orientation with its larger-diameter end 14 oriented above its smaller-diameter end 17, as is known in the art. The lower section 11 is arranged to receive at its lower end 17 a gate 20 for controlling discharge of the particulate material by gravity out of the hopper cone, as more clearly shown in FIGS. 6 and 7. Thus the gate 20 is disposed at a location where it is in communication with the discharge opening 18.

The lower section 11 may be formed from a plurality of sheets configured, for example by being sized and shaped, for interconnection for example by welding so as to form a generally conical wall. Once these sheets are interconnected during manufacturing they remain affixed to one another so that the lower section is unitarily shipped to the end user for assembly, as will be described in further detail later.

Referring to FIGS. 1-2 and FIGS. 8-10, in addition to the lower section 11 the kit includes a plurality of arcuate cone segments 22 each having a wall portion 23 defining an upper surface 25 for forming another portion of the hopper cone 2. The wall portion 23 extends along a circular curvature from a first side 27 to a second side 28 such that the upper surface 25 which faces generally upwardly is concavely curved therebetween. The wall portion 23 also is inclined from an arcuate upper end 30 to an arcuate lower end 31 such that the upper surface 25 is inclined therebetween. The wall portion 23 is in the form of a generally trapezoidal-shaped, relatively thin sheet which is elongated between the opposite sides 27, 28 of the wall portion and which is curved between these sides 27, 28 following a generally circular curvature. The trapezoidal sheet defining the wall portion has an arcuate upper edge defining the arcuate upper end 30 and a concentric shorter arcuate lower edge defining the arcuate lower end 31 such that these edges are parallel to one another when the sheet is curved following the circular curvature. Thus the upper surface 25 which faces generally upwardly and is defined on an interior side of the wall portion is concavely curved, and an underside 33 of the wall portion, which is opposite to the upper surface and faces generally downwardly, is convexly curved. Furthermore, the sheet is generally planar between the arcuate upper and lower edges so that the sheet is linearly inclined therebetween when the sheet is curved.

Referring to FIG. 5, the arcuate cone segments 22 are interconnectable to each other in side-by-side relation to form an annulus in which the wall portions 23 form a generally conical upper section 34, as shown more clearly in FIGS. 1 and 3. That is, to form the annulus the arcuate cone segments 22 are arranged adjacent one another with their sides 27, 28 facing that of the next arcuate cone segment. The upper section 34 therefore has a generally conical wall formed by the wall portions 23 of the cone segments 22 which is continuous in the circumferential direction of the annulus. The upper section 34 has a tapering diameter from an upper end 36 of the upper section which is collectively defined by the arcuate upper ends 30 of the wall portions to a lower end 37 of the upper section collectively defined by the arcuate lower ends 31 of the wall portions. The upper section 34 encompasses an axis B extending from an opening defined by the upper end 36 to a smaller-diameter opening defined by the lower end 37 of the upper section. The upper end 36 of the upper section is arranged to receive a cylindrical wall of the storage container (not shown), and the lower end 37 of the upper section is sized in diameter substantially equal to that of the upper end 14 of the lower section.

The upper section 34 formed by the interconnected arcuate cone segments 22 is connectable at its lower end 37 to the lower section 11 at the upper end 14 thereof so as to collectively form the hopper cone 2 as more clearly shown in FIGS. 1-4. The upper and lower sections, when joined, form an inverted generally conical wall which is continuous across a height of the hopper cone from the upper end 36 of the upper section 34 to the lower end 17 of the lower section 11 so as to suitably guide the particulate material stored above the hopper bottom within the storage container to the discharge opening 18. The axes A, B of the joined upper and lower sections are substantially coaxial.

As more clearly shown in FIGS. 8-10, each arcuate cone segment 22 includes at least one arcuate load-transfer member connected to the wall portion 23 and spanning from the first side 27 to the second side 28 generally following the curvature of the wall portion therebetween. In the illustrated arrangement, there is provided a pair of the arcuate load-transfer members 40A, 40B which are spaced from one another in a radial direction of the arcuate cone segment from the arcuate upper end 30 to the arcuate lower end 31. An outer one of the arcuate load-transfer members indicated at 40A is disposed at a periphery of the wall portion 23 at the upper end 30 thereof, and an inner one of the arcuate load-transfer members indicated at 40B is disposed at the underside 33 of the wall portion, opposite to the upper surface 25, intermediate the arcuate upper and lower ends 30, 31 of the wall portion but closer to the arcuate upper end 30 than to the arcuate lower end 31. Thus, generally speaking, the outer arcuate load-transfer member 40A is located at a closer radial position to the arcuate upper end 30 of the wall portion 23 than the inner arcuate load-transfer member 40B is thereto. Each arcuate load-transfer member is in the form of an elongated strip curved and oriented transversely to the wall portion, and generally vertically in the assembled hopper cone. The outer arcuate load-transfer member 40A has a top edge 41 spaced above the arcuate upper end 30 of the wall portion so as to present an upstanding flange to which the cylindrical wall of the storage container can be fastened when rested on the arcuate cone segment on an inner side of the outer load-transfer member 40A, such that the outer arcuate load-transfer member 40A encircles the cylindrical wall.

Each arcuate cone segment 22 is interconnectable with another arcuate cone segment in the annulus by lap plates 44A, 44B projecting from the arcuate load-transfer members 40A, 40B beyond the first side 27 or the second side 28 of the arcuate cone segment for overlapping with the arcuate load-transfer members of the other arcuate cone segment which is adjacent and the lap plates 44A, 44B are arranged to receive fasteners passed through the overlapped lap plates and the arcuate load-transfer members, for example by the inclusion of preformed apertures for receiving the fasteners that register with preformed apertures formed at the end of the load-transfer member opposite to that from which the lap plate 44A or 44B projects. Each lap plate 44A or 44B is connected to one of two curved faces of the respective arcuate load-transfer member, such as an outer one of the curved faces which is convexly curved in the case of the lap plate 44A projecting from the outer load-transfer member 40A or an inner one of the curved faces which is concavely curved in the case of the lap plate 44B projecting from the inner load-transfer member 40B. Each lap plate 44A, 44B and follows a curvature substantially concentric to the load-transfer member on which it is mounted so that, when side-by-side cone segments are interconnected, the load-transfer members of adjacent cone segments are arranged end-to-end and the lap plate is arranged flush with the same one of the inner, concavely curved or outer, convexly curved faces of the load-transfer member of the adjacent cone segment. In the illustrated arrangement, the lap plates 44A, 44B of the outer and inner load-transfer members 40A, 40B project from a common side of the arcuate cone segment which is the first side 27 as more clearly shown in FIG. 8.

In other words, each arcuate load-transfer member 40A or 40B includes a projecting lap plate 44A or 44B for interconnecting with a common type of arcuate load-transfer member of the adjacent cone segment 22, so as to form with the remaining interconnected cone segments a pair of radially spaced concentric rings or annuli in proximity to the upper end 36 of the hopper cone.

The legs 3 of the hopper bottom are arranged for connecting to the arcuate cone segments 22 between the two arcuate load-transfer members 40A, 40B. Thus upper ends of the legs 3 which connect to the hopper cone are located between the two arcuate load-transfer members 40A, 40B such that the load-transfer members provide suitable connection locations for coupling the arcuate cone segment to the respective leg. As the legs 3 of the hopper bottom are generally cylindrically and linearly elongated the arcuate load-transfer members are radially spaced apart by a distance substantially equal to a depth of the leg measured in a radial direction from an inner face 4A to an outer face 4B of the leg so as to receive the leg therebetween. Connecting the arcuate cone segments 22 to the legs 3 between the concentric rings formed by the interconnected arcuate load-transfer members 40A, 40B acts to transfer the load from the hopper cone into the legs which in turn transfer the load to the support surface.

As shown more clearly in FIGS. 1 and 5, typically the kit also includes a plurality of braces 45 to interconnect between the legs 3 and the arcuate cone segments 22 at circumferentially spaced locations from the legs 3. Similarly to the legs, the braces 45 are arranged to connect between the arcuate load-transfer members 40A, 40B. Upper ends of the braces 45 attach between the load-transfer members 40A, 40B at the inner load-transfer member 40B and a depending plate 47 which is connected at its upper edge to a bridging plate 49 spanning horizontally between the outer and inner load-transfer members. The depending mounting plate 47 is located at a radially inwardly spaced location from the outer load-transfer member 40A such that each brace 45 is inclined radially inwardly from its lower end attached to the leg 3 to its upper end connected between the load-transfer members.

Referring to FIGS. 8-10, each arcuate cone segment 22 further includes a connection member 56 connected to the underside 33 of the wall portion adjacent each one of the first and second sides 27, 28 and extending in the radial direction of the arcuate cone segment from the arcuate upper end 30 towards the arcuate lower end 31. Thus there are two connection members 56, one at each side 27, 28 of the arcuate cone segment. Each connection member 56 is arranged for butting engagement with the connection member 56 of another arcuate cone segment in the annulus for forming the upper section 34 and is arranged to receive fasteners through the abutted connection members at radially spaced positions thereon. The connection member 56 therefore is located at the side of the arcuate cone segment 22 so as to be available for butting engagement by the corresponding member 56 of the adjacent cone segment. Each connection member 56 is in the form of an elongated planar strip defining a planar abutment surface and oriented transversely to the wall portion 23 so as to lie generally vertically, with parallel top and bottom edges extending from the inner load-transfer member 40B at an incline in the radial direction similarly to the wall portion 23. For receiving the fasteners, the connection member 56 defines a plurality of radially spaced apertures 59 which are elongated slightly in the radial direction so as to permit alignment in the radial direction between adjacent cone segments 22. The apertures 59 are arranged in a linear row, and there is also provided an auxiliary connection member 61 spanning radially between the two arcuate load-transfer members 40A, 40B with elongated apertures 63 which are arranged in a generally horizontal row. Thus the combination of the abuttable radially extending connection members and at least one arcuate load-transfer member with lap plate provides two types of interconnection of adjacent arcuate cone segments.

In the foregoing manner the arcuate cone segments 22 are interconnected to form the upper section 34 of the hopper cone.

In order to connect the upper cone section 34 to the lower cone section 11, the lower section includes an annular connection member 65 at the upper end 14 thereof and on an exterior side 67 of the lower section that is arranged to receive fasteners 68 passed therethrough (FIGS. 6 and 11-13), and each arcuate cone segment 22 includes an arcuate connection member 69 connected to the underside 33 of the wall portion adjacent but recessed from the arcuate lower end 31 and extending in a direction from the first side 27 to the second side 28 generally following the curvature of the wall portion 23 between the first and second sides (FIGS. 8-10 and 12-13) for coupling to the annular connection member 65. The lower end 37 of the upper cone section 34 formed by the interconnected arcuate cone segments 22 is sized in outer diameter substantially equal to an inner diameter of the upper end 14 of the lower section 11, that is a diameter on an interior side of the lower section at its upper end, so that the lower end 37 of the upper section 34 can overlap the interior side of the lower section 11 at its the upper end 14 with the arcuate connection members 69 of the interconnected arcuate cone segments 22 which are recessed radially outwardly from the arcuate lower ends 31 consequently being presented at or adjacent the annular connection member 65 of the lower section. The annular connection member 65 of the lower section 11 spans the full circumference of the upper end 14 of the lower cone section 11, and the arcuate connection members 69 of the interconnected cone segments 22 form a continuous annulus or ring as each individual arcuate connection member 69 spans from one side 27 to the other at 28 of the wall portion 23 of each arcuate cone segment. The arcuate connection member 69 of each cone segment 22 also spans from a lower end of the radial connection member 56 to that of the opposite connection member 56 of the same cone segment. Each of the connection members 65 and 69 are in the form of elongated strips oriented generally vertically and thus transversely to the wall to which they're connected, and which are curved to follow the curvature of the corresponding one of the lower section 11 and the arcuate cone segment 22. This overlapping of the upper section with the lower section resists the possibility of the particulate material becoming stuck at a seam formed between abutted ends of the two cone sections during discharge by gravity out of the hopper cone. FIGS. 11-13 show a first embodiment in which the only direct interconnection between the upper and lower sections of the hopper cone is facilitated by the annular connection member 65 and the individual arcuate connection members 69 of the cone segments. FIGS. 14-16 show a second embodiment of hopper cone in which additionally to the interconnection facilitated by the foregoing elements, the upper and lower sections are interconnected through a thickness of the overlapped walls. In such an embodiment, the wall portion 23 of each arcuate cone segment is thickened at 72 between the arcuate lower edge 31 and the arcuate connection member 69 so as to strengthen the wall portion 23 for receiving fasteners 73 passed through a thickness thereof when the lower end 37 of the upper section formed by the interconnected arcuate cone segments is overlapped with the interior side at the upper end 14 of the lower section 11. Similarly, the lower section 11 is thickened at 74 between its interior and exterior sides adjacent the annular connection member 65 so as to strengthen the lower section for receiving the fasteners 73 passed through a thickness thereof when the upper end 14 of the lower section is overlapped with the lower end 37 of the upper section formed by the interconnected arcuate cone segments. For either the arcuate cone segments 22 or the lower section 11, thickening of the wall thereof is accomplished by providing a plurality of additional plates at spaced locations corresponding to locations of the fasteners 73, which are connected to the sheet forming the wall adjacent the overlapped edge thereof. As shown in the second embodiment of FIGS. 14-16, the fasteners 68 passed through the annular connection member 65 of the lower section and the arcuate connection members 69 of the interconnected arcuate cone segments are offset from the fasteners 73 passed through the thicknesses of the upper and lower sections angularly of the axis A of the lower section. Thus, the same number of fasteners can be used to interconnect the upper and lower sections in both embodiments of the hopper cone of FIGS. 11-16 at the same angularly spaced locations of the axis A, B of the assembled hopper cone.

The hopper cone 2 is intended to be supported with its bottom spaced above the underlying support surface so as to suitably access the discharged content, and therefore for forming the legs 3 of the hopper bottom 1, with reference back to FIGS. 8-10, each arcuate cone segment 22 includes a plurality of stub leg portions 77 connected to the wall portion 23 at spaced locations across the curvature thereof and extending from the convexly curved underside 33 of the wall portion, which is opposite to the upper surface 25, generally parallel to the axis B of the upper section 34 to lower ends 79 of the stub leg portions which are disposed generally at a common height below the arcuate upper end 30 of the wall portion as the lower end 31 of the wall portion. More specifically, when the arcuate connection member 69 for coupling the cone segment 22 to the lower section 11 has a bottom edge 82 disposed below the arcuate lower end 31, as in the illustrated arrangement, the lower ends 79 of the stub leg portions are disposed at a substantially common height with the bottom edge 82 of the arcuate connection member. The lower ends 79 of the stub leg portions define planes which are arranged to be oriented horizontally. Thus the arcuate cone segments 22 can be more readily stacked as both the wall portion and the stub leg portion have a substantially common height and bottoms thereof lie in a substantially common plane. The stub leg portions 40 form a portion of the legs 3 of the hopper bottom but are unitary with the wall portions 23 in forming the arcuate cone segments 22 such that after being interconnected during manufacturing they are shipped unitarily to the end user for assembly.

Referring to FIGS. 5 and 17, the kit further includes a plurality of leg components 85 distinct from the stub leg portions 77 extending between upper and lower ends 87, 88 of the leg components. The upper ends 87 of the leg components are connectable to the lower ends 79 of the stub leg portions 40, and the leg components are sized in height between the upper and lower ends 87, 88 larger than a height of the lower section 11 from the lower end 17 to the upper end 14 thereof, so as to hold the discharge opening 18 at a spaced height above the support surface on which the hopper bottom 1 is rested. The inclined braces 45 interconnect the leg components 85 and the arcuate cone segments 22 at circumferentially spaced locations from the stub leg portions 77 which are vertically in-line with the leg components.

Referring to FIGS. 18-19, the kit generally includes a plurality of horizontal braces 90 for further rigidifying connection between the hopper cone 2 and the legs 3. The horizontal braces 90 are in the form of a plurality of linearly elongated members extending radially outwardly at angularly spaced positions of one another from the lower end 17 of the lower section 11 of the hopper cone to each of the leg components 85. The horizontal braces 90 are disposed in a substantially common plane and connect at one end to the lower section 11 at the lower end 17 thereof and at an opposite end to the respective leg component 85.

Referring to FIGS. 1, 3, 5 and 20, the legs 3 of the hopper cone may be interconnected so as to maintain the legs in fixed relation to one another, for improved stability of the hopper bottom, by a footing 4 which in the kit of the present invention is formed by a plurality of arcuate footing segments 94 each having a top surface 95 for supporting the lower ends of the legs 3, defined by the lower ends 88 of the leg components 85, and a bottom surface 97 arranged for resting on the support surface. The arcuate footing segments 94 each extend along a generally circular curvature from a first end 99 to a second end 100 and are interconnectable to each other in end-to-end relation to form an annulus which is sized to underlie the lower ends of the legs 3 disposed in circumferentially spaced relation about the hopper cone 2 for supporting the hopper bottom on the support surface.

Each arcuate footing segment 94 comprises at least one linear portion 103 which extends along a substantially linear path from one end 104 of the portion to the other 105 and at least one elbow portion 108 which is connected at one of its opposite sides 109 to one of the ends of a respective one of the at least one linear portion. The arcuate footing segment 94 may include a plurality of each of the linear and elbow portions depending on the size of the hopper cone, as in the illustrated arrangement. Typically, the arcuate footing segment has a linear portion 103 at one end 99 of the segment and an elbow portion 103 at the other end 100 so that the segment terminates with different types of portions. As more clearly shown in FIG. 21, the elbow portion 108 is generally pie-shaped between the opposite sides 109 so as to have a tapering width between the sides from an outer end 111 to an inner end 112 which is arranged to be located radially inwardly of the outer end with respect to the hopper bottom. The elbow portion 108 has a lower surface 114 arranged for resting on the support surface, so as to define part of the bottom surface 97 of the footing segment, and an upper surface 115 defining a leg-mounting location 116 for receiving the lower end of one of the legs mounted to the elbow portion. The elbow portion 108 defines an internal cavity 117 between the upper and lower surfaces 114, 115, the opposite sides 109, and the inner and outer ends 111 and 112, and includes a strengthening rib 119 bridging the internal cavity 117 in a direction from the lower surface 114 to the upper surface 115 and disposed beneath the leg-mounting location on the upper surface. The strengthening rib 119 is in the form of a plate oriented substantially vertically with tabs 121 at spaced locations around the plate's periphery that are projecting in a plane of the plate for mating in slots 122 formed in the elbow portion, and the rib is welded at its tabs to the elbow portion.

Referring to FIGS. 5 and 22, the ends 99, 100 of each arcuate footing segment 94 are arranged for butting engagement each with one of the ends 99 or 100 of another arcuate footing segment and to receive fasteners passed through the abutted ends of different arcuate footing segments so as to join the footing segments in forming the annular footing 4. Each arcuate footing segment 94 further includes a generally horizontally projecting flange extending beyond one of the ends 99 or 100 for resting on top of the adjacent arcuate footing segment when connected in the annulus of the interconnected arcuate footing segments for reducing a shear force exerted on the fasteners passed through the abutted ends. In the illustrated arrangement, the load-transfer flange is formed by a plurality of tabs 125 spaced across the end of the arcuate footing segment, which are carried on an elbow portion 108 defining one of the ends of the respective footing segment as the elbow portion directly receives one of the legs 3 thereon. The load-transfer flange/tabs engage the top surface 95 of the adjacent arcuate segment as the two segments are otherwise distinct and connected simply by fasteners passed in an orientation which is transverse to the load exerted upon the footing segments.

This arrangement provides a kit which is transportable on a transport truck for subsequent assembly at a site in which the lower section 11 can be arranged by sizing its upper end 14 in diameter so as to span a width of the transport truck which is measured laterally between opposite sides crosswise to a longitudinal direction of the truck between forward and rear ends which is parallel to a forward transport direction of the transport truck. Typically, a conventional width transport truck can legally transport a load which is oversized relative to its width. Therefore, by arranging the lower section 11 in diametric size as described by the foregoing, this maximizes the size of the hopper cone 2 which can be shipped, while reducing the number of parts to be subsequently assembled by the user. Thus a relatively large hopper cone can be formed from a limited number of separate components all of which can be readily shipping together on a single transport truck. Also, the conical shape of the lower section 11 enables similarly sized lower sections to be stacked in inverted orientation (relative to normal use of the hopper cone) during shipping on a transport truck, thus increasing the number of hopper cones which may be concurrently shipped.

In use, the various components of the kit are shipping in separated, disconnected condition relative to each another typically on a transport truck such as a semi-tractor towing a flatbed trailer. In order to maximize the shipping capacity of a single truck, the lower section 11 of the hopper cone can occupy a full width of the transport truck and typically extends beyond the sides of the transport truck defining the width. A plurality of the lower sections 11 can be stacked in inverted orientation (relative to the orientation of the section in normal use) and in a nesting fashion as the lower section provides a tapering shape which is suited for nested stacking. The arcuate cone segments 22 are typically positioned on the transport truck to one side of the lower section, and likewise can be generally vertically stacked one on top of the other because a bottom of each arcuate cone segment defines a plane. Additional elements may be used to support the arcuate cone segments in a stacked configuration.

Once the kit has reached its destination site where it will subsequently be assembled, the user has received as part of the kit at least a generally conical first cone section 11 having a tapering diameter from a first end 14 to the second end 17 such that the first end 14 is sized diametrically larger than the second end 17, and a plurality of arcuate cone segments 22 each defining an inclined concavely curved wall 23 following a generally circular curvature, all of which can collectively form a hopper cone. First, the arcuate cone segments 22 are connected to form an annulus in which the walls 23 of the arcuate cone segments collectively form a generally conical second cone section 34 having a tapering diameter from one end 36 to an opposite end 37 which has a diameter substantially equal to that of the second end 17 of the first cone section 11. This interconnection is achieved by abutting the side connection members 56 and passing fasteners therethrough, and by connecting the overlapped lap plates 44A, 44B to the corresponding arcuate load-transfer member 40A or 40B of the adjacent cone segment. Typically, the upper section 34 is formed in inverted orientation, that is, each of the individual arcuate cone segments are inverted and connected to each other in the inverted orientation.

After the arcuate cone segments are connected in the annulus, the opposite end 37 of the formed second cone section 34 is connected to the first end 14 of the first cone section 11 so as to form the hopper cone 2. This interconnection is achieved by located the lower end 37 of the upper section within the upper end 14 of the lower section 11 so that a bottom end of the conical wall of the upper section 34 overlaps a top end of the conical wall of the lower section 11, such that the annular connection member 65 is located at or adjacent the ring-forming arcuate connection members 69 of the interconnected cone segments 22. In certain arrangements where the walls of the overlapped sections can be interconnected, this is also done. The lower section 11 is connected to the upper section in inverted orientation such that the lower end is lowered while in inverted orientation onto the upper section which is also maintained inverted.

After the lower section 11 is attached to the upper section 34, the leg components 85 may be connected to the stub leg portions 77 while the interconnected components remain in inverted orientation.

Next, the horizontal braces 90 and the inclined braces 45 are connected between the formed legs 3 and the formed hopper cone 2 while the already interconnected components remain in inverted orientation.

The footing 4 is then assembled by interconnecting the individual arcuate footing segments 94 into an annulus, and afterwards the formed footing 4 is lowered in inverted orientation onto the already interconnected legs 3, braces 45 and 90, and hopper cone 2 which are in inverted orientation.

With the hopper bottom substantially assembled it may then be repositioned so that the footing 4 is resting on the support surface and the hopper cone 2 is disposed thereabove.

The scope of the claims should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the specification as a whole. 

1. A kit for forming a hopper bottom of a particulate material storage container, the hopper bottom including a hopper cone, the kit comprising: a generally conical lower section for forming a first portion of the hopper cone, the lower section encompassing an axis and having a tapering diameter from an upper end defining an opening to a lower end arranged to define a discharge opening of the hopper cone through which particulate material can pass by gravity, the lower section being arranged to receive at its lower end a gate for controlling discharge of the particulate material by gravity out of the hopper cone; a plurality of arcuate cone segments each having a wall portion defining an upper surface for forming another portion of the hopper cone, the wall portion extending along a circular curvature from a first side to a second side such that the upper surface is concavely curved therebetween and the wall portion being inclined from an arcuate upper end to an arcuate lower end such that the upper surface is inclined therebetween; the arcuate cone segments being interconnectable to each other in side-by-side relation to form an annulus in which the wall portions form a generally conical upper section having a tapering diameter from an upper end of the upper section which is collectively defined by the arcuate upper ends of the wall portions to a lower end of the upper section collectively defined by the arcuate lower ends of the wall portions, the upper end of the upper section being arranged to receive a cylindrical wall of the storage container and the lower end of the upper section being sized in diameter substantially equal to that of the upper end of the lower section; and the upper section formed by the interconnected arcuate cone segments being connectable at its lower end to the lower section at the upper end thereof so as to collectively form the hopper cone.
 2. The kit of claim 1 wherein each arcuate cone segment includes a pair of arcuate load-transfer members each connected to the wall portion and spanning from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the arcuate load-transfer members being spaced from one another in a radial direction of the arcuate cone segment from the arcuate upper end to the arcuate lower end, the arcuate cone segment being interconnectable with another arcuate cone segment in the annulus by lap plates projecting from the arcuate load-transfer members beyond the first side or the second side of the arcuate cone segment for overlapping with the arcuate load-transfer members of said another arcuate cone segment and arranged to receive fasteners passed through the overlapped lap plates and the arcuate load-transfer members.
 3. The kit of claim 2 further including a plurality of legs arranged for connecting to the arcuate cone segments between the arcuate load-transfer members so as to hold the discharge opening of the hopper cone at a spaced height above a support surface on which the hopper bottom is rested.
 4. The kit of claim 3 wherein there are provided a plurality of braces to interconnect between the legs and the arcuate cone segments at circumferentially spaced locations from the legs which are arranged to connect between the arcuate load-transfer members.
 5. The kit of claim 2 wherein an outer one of the arcuate load-transfer members is disposed at a periphery of the wall portion at the arcuate upper end thereof, and an inner one of the arcuate load-transfer members is disposed at an underside of the wall portion, opposite to the upper surface, intermediate the arcuate upper and lower ends of the wall portion but closer to the arcuate upper end than to the arcuate lower end.
 6. The kit of claim 1 wherein: each arcuate cone segment includes a connection member connected to an underside of the wall portion, which is opposite to the upper surface, adjacent each one of the first and second sides and extending in a radial direction of the arcuate cone segment from the arcuate upper end towards the arcuate lower end, the connection member being arranged for butting engagement with the connection member of another arcuate cone segment in the annulus for forming the upper section and being arranged to receive fasteners through the abutted connection members at radially spaced positions thereon; and each arcuate cone segment further includes an arcuate load-transfer member connected to the wall portion and spanning from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the arcuate cone segment being interconnectable with another arcuate cone segment in the annulus by a lap plate projecting from the arcuate load-transfer member beyond one of the first and second sides for overlapping with the arcuate load-transfer member of said another arcuate cone segment and arranged to receive fasteners passed through the overlapped lap plate and the arcuate load-transfer member.
 7. The kit of claim wherein the lower section includes an annular connection member at the upper end thereof and on an exterior side of the lower section that is arranged to receive fasteners passed therethrough, and each arcuate cone segment includes an arcuate connection member connected to an underside of the wall portion, which is opposite to the upper surface, adjacent but recessed from the arcuate lower end and extending in a direction from the first side to the second side generally following the curvature of the wall portion between the first and second sides, the lower end of the upper section formed by the interconnected arcuate cone segments being sized in outer diameter substantially equal to an inner diameter of the upper end of the lower section so that the lower end of the upper section can overlap an interior side of the lower section at its the upper end with the arcuate connection members of the interconnected arcuate cone segments being presented at or adjacent the annular connection member of the lower section for coupling thereto.
 8. The kit of claim 7 wherein the wall portion of each arcuate cone segment is thickened between the arcuate lower edge and the arcuate connection member so as to strengthen the wall portion for receiving fasteners passed through a thickness thereof when the lower end of the upper section formed by the interconnected arcuate cone segments is overlapped with the interior side at the upper end of the lower section.
 9. The kit of claim 7 wherein the lower section is thickened between its interior and exterior sides adjacent the annular connection member so as to strengthen the lower section for receiving fasteners passed through a thickness thereof when the upper end of the lower section is overlapped with the lower end of the upper section formed by the interconnected arcuate cone segments.
 10. The kit of claim 7 wherein, when the wall portion of each arcuate cone segment is thickened between the arcuate lower edge and the arcuate connection member so as to strengthen the wall portion for receiving fasteners passed through a thickness thereof when the lower end of the upper section formed by the interconnected arcuate cone segments is overlapped with the interior side at the upper end of the lower section, the lower section is thickened between its interior and exterior sides adjacent the annular connection member so as to strengthen the lower section for receiving fasteners passed through a thickness thereof when the upper end of the lower section is overlapped with the lower end of the upper section formed by the interconnected arcuate cone segments, and the fasteners passed through the annular connection member of the lower section and the arcuate connection members of the interconnected arcuate cone segments are offset from the fasteners passed through the thicknesses of the upper and lower sections angularly of the axis of the lower section.
 11. The kit of claim 1 wherein each arcuate cone segment includes a plurality of stub leg portions connected to the wall portion at spaced locations across the curvature thereof and extending from an underside of the wall portion, which is opposite to the upper surface, generally parallel to the axis to lower ends of the stub leg portions which are disposed generally at a common height below the arcuate upper end of the wall portion as the lower end of the wall portion.
 12. The kit of claim 11 further including a plurality of legs distinct from the stub leg portions and sized in height between upper and lower ends of the legs larger than a height of the lower section from the lower end to the upper end thereof, the upper ends of the legs being connectable to the lower ends of the stub leg portions so as to hold the discharge opening at a spaced height above a support surface on which the hopper bottom is rested, the legs being connected to support the hopper cone in fixed relation to the legs including a plurality of braces provided to interconnect between the legs and the arcuate cone segments at circumferentially spaced locations from the stub leg portions.
 13. The kit of claim 12 wherein, when each arcuate cone segment includes an arcuate connection member connected to the underside of the wall portion adjacent but recessed from the arcuate lower end and extending in a direction from the first side to the second side generally following the curvature of the arcuate cone segment between the first and second sides, and the arcuate connection member has a bottom edge disposed below the arcuate lower end, the lower ends of the stub leg portions are disposed at a substantially common height with the bottom edge of the arcuate connection member.
 14. The kit of claim 1 further including: a plurality of legs arranged for connecting to the arcuate cone segments so as to hold the discharge opening of the hopper cone at a spaced height above a support surface on which the hopper bottom is rested; and a plurality of arcuate footing segments each having a top surface for supporting the lower ends of the legs and a bottom surface arranged for resting on the support surface, the arcuate footing segments each extending along a generally circular curvature from a first end to a second end and being interconnectable to each other in end-to-end relation to form an annulus which is sized to underlie the lower ends of the legs disposed in circumferentially spaced relation about the hopper cone for supporting the hopper bottom on the support surface.
 15. The kit of claim 14 wherein each arcuate footing segment comprises at least one linear portion which extends along a substantially linear path from one end to the other and at least one elbow portion which is connected at one of its opposite sides to one of the ends of a respective one of the at least one linear portion, the elbow portion being generally pie-shaped between the opposite sides so as to have a tapering width between the sides from an outer end to an inner end which is arranged to be located radially inwardly of the outer end with respect to the hopper bottom, the elbow portion having a lower surface arranged for resting on the support surface and an upper surface defining a leg-mounting location for receiving the lower end of one of the legs mounted to the elbow portion, the elbow portion defining an internal cavity between the upper and lower surfaces, the opposite sides, and the inner and outer ends, and including a strengthening rib bridging the internal cavity in a direction from the lower surface to the upper surface and disposed beneath the leg-mounting location on the upper surface.
 16. The kit of claim 14 wherein the ends of each arcuate footing segment are arranged for butting engagement each with one of the ends of another arcuate footing segment and to receive fasteners passed through the abutted ends of different arcuate footing segments, each arcuate footing segment further including a generally horizontally projecting flange extending beyond one of the ends for resting on top of the adjacent arcuate footing segment when connected in the annulus of the interconnected arcuate footing segments for reducing a shear force exerted on the fasteners passed through the abutted ends.
 17. A method for forming a hopper bottom of a particulate material storage container, the hopper bottom including a hopper cone, the method comprising: providing a kit for forming the hopper cone including: a generally conical first cone section having a tapering diameter from a first end to the second end such that the first end is sized diametrically larger than the second end; a plurality of arcuate cone segments each defining an inclined concavely curved wall following a generally circular curvature; connecting the arcuate cone segments to form an annulus in which the walls of the arcuate cone segments collectively form a generally conical second cone section having a tapering diameter from one end to an opposite end which has a diameter substantially equal to that of the second end of the first cone section; after the arcuate cone segments are connected in the annulus, connecting the opposite end of the formed second cone section to the first end of the first cone section so as to form the hopper cone. 